Meat processing devices to control meat slab dimensions

ABSTRACT

A meat processing device for defining a uniform shape of a pork belly, and including a frame, a shoulder defining a confinement space with the frame, and a tine and a retaining member for securing the meat in the confinement space.

CROSS REFERENCE TO RELATED APPLICATION

This application is a continuation-in-part of U.S. application Ser. No.16/197,792, filed Nov. 21, 2018, which claims the benefit of U.S.Provisional Application No. 62/594,343, filed Dec. 4, 2017, thedisclosures of which are incorporated by reference herein.

FIELD AND BACKGROUND OF THE INVENTION

The present invention relates generally to meat processing equipment,and more particularly to hanging hooks (commonly called “combs”) and/orlower devices for securing pork bellies to be processed into bacon.Large volume bacon manufacturers convert pork bellies into slices ofbacon suitable for food service or retail customers. One of their goalsis to produce as many dimensionally uniform and unblemished slices aspossible from pork bellies that have a wide variation in physicaldimensions.

Steps in the processing of pork bellies into bacon usually include: 1)injecting a water solution usually containing salt, sugar, sodiumphosphates, sodium ascorbate or sodium erythorbate, sodium nitrite andsometimes flavorings into the belly; 2) inserting a hanging hook or“comb” into one end of the injected belly and hanging the belly on arack or trolley; 3) moving the rack or trolley into a smokehouse to heatand smoke the pork bellies; 4) chilling the processed pork; 5) removingthe combs; 6) forming (or “pressing”) the processed pork belly into arectangular block or slab; and 7) slicing and packaging the bacon. Manypork producers try to impale the cutaneous trunci (CT) muscle of thepork belly on one or more tines of a comb to improve slicing yields.

Large bacon manufacturers use slicing equipment that can exceed 1000slices per minute. To enable these speeds, the bacon slab is chilled toa temperature that generally ranges from 19° F. to 25° F. Temperaturesin the upper part of this range should produce firm, but not solid slabsthat are usually more suitable for both the pressing and slicing stepsand which yield subsequently more high quality slices per slab than whenpressing and slicing at higher or lower temperatures.

It is common to use a bacon slab pressing device after smoking to formthe pork belly slab into a uniformly rectangular shape, so that theresulting slices are of uniform width and length. Uniform slices aredesirable for both aesthetics and for packaging efficiency. Smoking,chilling and pressing pork bellies enables the bacon to be sliced intoslices that land on a conveyor flat and that stay in uniform shingled orflat drafts (groups of shingled slices with a desired total weight orquantity for packaging) that can then be easily transferred to apackaging line. Pork belly slabs pressed at an overly warm temperaturemay not stay as a rectangular block, and the warm slices often stick tothe slicer blade and land on the conveyor twisted, folded, and not flat.If the slices are too cold, they may land flat on the conveyor, butslide on the conveyor or each other, also resulting in a non-uniformdraft. In either case the drafts are not acceptable for packagingwithout extra manual attention.

Pressing bacon into more uniform shapes requires the movement of bacontissues. If the slabs are too cold, movement of the internal tissues maycause separation of the tissues. The greater the movement of thosetissues during pressing, especially at colder temperatures, the moreinternal cracking, breaking and seam separation can occur in theresultant bacon slices. Previous recommendations using an ANCO baconpress were that the movement of tissues should not exceed 15% of theoverall slab dimension. This 15% is routinely exceeded by most baconproducers because the width of the upper end of the raw belly is oftenmuch greater than 115% of the final dimensions.

Many of the above-described problems are the result of pork belliesstretching, folding, and otherwise forming into irregular shapes duringthe smoking/heating process while hanging on hangers/combs during thesmoking process. Thus, there is a need for an improved pork bellyhanging method and devices that minimize the excessive amount ofdimension correction and tissue movement that causes internal crackingand/or seam separation and/or breaking during the pressing operation.

SUMMARY OF THE INVENTION

The present invention produces bacon slab dimensions suitable forslicing by controlling both the width and thickness of both thetop/flank end and the bottom/brisket end of the hanging belly during thesmoking and heating process to better conform to the desired slicedimensions needed in the finished package while minimizing damage to theslab and slices. The bottom/brisket end of the hanging belly has the endformed flat or nearly flat, so that slicing will result in higher firstquality bacon slicing yields. If it is flat or nearly flat, the first orsecond slice should be acceptable for packaging. By maintaining thewidth of the top/flank end, it has been found that gravity and heatduring the smoking/heating process result in a more uniform belly widthfrom the top to the bottom of the pork belly, which results in lesstissue movement and damage during pressing and resulting in higheryields. Pork bellies hung with the present invention become narrower andmore dimensionally uniform after processing than those hung withconventional methods. This means bellies can be hung closer together ontrolleys during the smoking operation, thus increasing the number ofbellies on a trolley. This results in a significant increase inprocessing capacity.

Meat processing devices in accordance with the present invention, can beused on the top and/or the bottom of both ends of a pork belly. A topmeat processing device has a hook for hanging on a trolley and a bottommeat processing device need not have a hook. The bottom meat processingdevice preferably includes a locking mechanism to maintain a cover in aclosed position, but a locking mechanism is not typically necessary on atop meat processing device, although a locking device could be used.

A meat processing device for the top or the bottom of a pork belly inaccordance with the present invention includes a frame having a firstend portion and a second end portion; a shoulder joined to the first endportion of the frame to at least partially define a confinement spacewith the frame; and a frame tine joined to and extending outwardly fromthe frame and into the confinement space. The meat processing device caninclude a second frame tine joined to and extending outwardly from theframe and into the confinement space. The meat processing device canalso include a second shoulder joined to the second end portion of theframe to at least partially define the confinement space with the frameand the shoulder.

The meat processing device can further include a cover joined to theframe to at least partially define the confinement space. The cover canbe fixed or hinged to the frame to pivot between an open position and aclosed position to at least partially define the confinement space, andinclude a cover tine joined to the cover and extending toward the frame.

The cover can include a first portion hinged to the frame for movementbetween an open position and a closed position, and a second portiondisposed at an angle to the first portion, and spaced apart from theframe in the closed position to at least partially define theconfinement space. This embodiment is preferred for a bottom meatprocessing device.

The meat processing device when used on the top of a pork belly can alsoinclude a hanging hook joined to the frame for hanging the device on arack or a trolley.

The meat processing device frame can have a central portion between thefirst portion and the second portion; and at least a portion of theshoulder extends toward the central portion to define a taperedconfinement space.

The meat processing device cover can also be releasably engaged to theshoulder when in the closed position, and the cover can include ashoulder lock component on the shoulder for releasably engaging a coverlock component in the closed position. The shoulder can include a numberof shoulder lock components that can be selected for engagement with thecover lock component on the cover.

An upper or top meat processing device can be used with a second orlower meat processing device having a second frame having a first endportion and a second end portion; a frame tine joined to and extendingoutwardly from the second frame between the first end portion and thesecond end portion; and a shoulder joined to the first end portion ofthe second frame to at least partially define a confinement space withthe second frame.

The lower meat processing device can further include two or more covershinged to the frame to pivot between open positions and closed positionsto at least partially define the confinement space.

Further features and benefits of the present invention are included inthe detailed description below.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a front view of a pork belly hanging on a conventional 9″bacon comb;

FIG. 2A is a side view of a pork belly hanging on a conventional 9″bacon comb;

FIGS. 2B and 2C show side view depictions of pork bellies hanging onconventional 9″ bacon combs with various meat defects;

FIG. 3 is a front view of a bacon belly hanging on a conventional 12″bacon comb;

FIG. 4 shows a meat processing device defining a confinement space toachieve a substantially constant pork slab width in accordance with thepresent invention;

FIG. 5 is a perspective view of an alternate meat processing device witha cover for an upper end of a pork belly in accordance with the presentinvention;

FIG. 6 is a perspective view of a meat processing device with a coverfor a lower end of a pork belly in accordance with the presentinvention;

FIG. 7 is a perspective view of an alternate meat processing device witha cover, in accordance with the present invention;

FIG. 8 is a perspective view of an alternate meat processing device witha cover, in accordance with the present invention;

FIG. 9 is a perspective view of an alternate meat processing device witha cover, in accordance with the present invention;

FIG. 10 is a perspective view of an alternate meat processing devicewith a cover, in accordance with the present invention;

FIG. 11 is a perspective view of an alternate meat processing devicewith a cover, in accordance with the present invention;

FIG. 12 is a front view of a meat processing device for the top of apork belly and a meat processing device for the bottom end of a porkbelly, attached to a pork belly in accordance with the presentinvention;

FIG. 13 is a front view of a meat processing device for the top of apork belly and a meat processing device for the bottom end of a porkbelly, attached to a pork belly in accordance with the presentinvention;

FIG. 14 is a side view of the top and bottom meat processing devices ofFIG. 13 attached to a pork belly;

FIG. 15 is a top view of the top meat processing device of FIG. 13;

FIG. 16 is a bottom view of the bottom meat processing device of FIG.13;

FIG. 17 is a perspective view of the top meat processing device of FIG.13 and joined to a pork belly;

FIG. 18 is a perspective view of the bottom meat processing device ofFIG. 13 and joined to a pork belly;

FIG. 19 is another perspective view of the top and bottom meatprocessing devices of FIG. 13 and joined to a pork belly;

FIG. 20 is a perspective view from the front upper right of a top meatprocessing device in accordance with the present invention;

FIG. 21 is a perspective view from the front upper left of a top meatprocessing device in accordance with the present invention;

FIG. 22 is a perspective view from the rear upper left of a top meatprocessing device in accordance with the present invention;

FIG. 23 is a slightly different perspective view from the rear upperleft of a top meat processing device in accordance with the presentinvention;

FIG. 24 is a rear view of the top meat processing device of FIG. 21;

FIG. 25 is a top view of the top meat processing device of FIG. 21;

FIG. 26 is a bottom view of the top meat processing device of FIG. 21;

FIG. 27 is a left side view of the top meat processing device of FIG.21;

FIG. 28 is an upper right front perspective view of a bottom meatprocessing device in accordance with the present invention;

FIG. 29 is a bottom right perspective view of the meat processing deviceof FIG. 28;

FIG. 30 is a partial upper left perspective view of the meat processingdevice of FIG. 28;

FIG. 31 is a left side view of the bottom meat processing device of FIG.28 with a cover in an open position;

FIG. 32 is a left side view of the bottom meat processing device of FIG.28 with the cover in a first closed position;

FIG. 33 is a left side view of the bottom meat processing device of FIG.28 with the cover in a second closed position;

FIG. 34 is a left side view of the bottom meat processing device of FIG.28 with the cover in a third closed position;

FIG. 35 is an upper left front perspective view of the bottom meatprocessing device of FIG. 28 with two covers in the open position;

FIG. 36 is an upper left rear perspective view of the bottom meatprocessing device of FIG. 28 with one cover open and one cover closed;

FIG. 37 is a partial perspective view of an alternate bottom meatprocessing device;

FIG. 38 is a partial perspective view of the alternate bottom meatprocessing device of FIG. 37; and

FIG. 39 is an upper right front view of a trolley and meat processingsystem in accordance with the present invention.

FIG. 40 is a perspective view of an alternate embodiment of a meatprocessing device in accordance with the present invention;

FIG. 41 is a perspective view of the meat processing device of FIG. 40with a retaining pin in a closed position;

FIG. 42 is a front view of the meat processing device of FIG. 40;

FIG. 43 is a side view of the meat processing device of FIG. 40;

FIG. 44 is a bottom view of the meat processing device of FIG. 40;

FIG. 45 is a perspective view of an alternate embodiment of a meatprocessing device in accordance with the present invention;

FIG. 46 is a front view of the meat processing device of FIG. 40;

FIG. 47 is a side view of the meat processing device of FIG. 40;

FIG. 48 is a bottom view of the meat processing device of FIG. 40;

FIG. 49 is a side view of a retaining pin in accordance with the presentinvention;

FIG. 50 is a perspective view of an alternate embodiment of a meatprocessing device in accordance with the present invention;

FIG. 51 is a perspective view of the meat processing device of FIG. 40with a retaining pin in a closed position;

FIG. 52 is a top view of the meat processing device of FIG. 40;

FIG. 53 is a side view of the meat processing device of FIG. 50;

FIG. 54 is a side view of the meat processing device of FIG. 40;

FIG. 55 is a perspective view of the meat processing device of FIG. 40attached to a lower end of a pork belly;

FIG. 56 is a front view of a number of meat processing devices in anested storage configuration; and

FIG. 57 is a side view of the nested meat processing devices of FIG. 55.

DETAILED DESCRIPTION OF THE INVENTION

In the following detailed description of the invention, the samereference numerals will be used for the same or similar components beingdescribed in each of the drawings. Also, the present invention is mostsuitable for processing pork bellies into pork slabs for being slicedinto bacon, but the present invention can be used to process other cutsand types of meat, as well.

Prior meat processing devices are depicted in FIGS. 1 through 3 as apork belly hanger 50 or “comb.” The comb 50 includes tines 51 that areinserted into a pork belly 52, then hung on a rack or trolley for asmoking process. Many sizes of hangers 50 or bacon combs are used in thebacon industry, including 9-inch and 12-inch bacon combs. With theshorter (9-inch) combs, there often is a much wider part of the porkbelly on either side of the end of the comb 50, as compared to the wider(12-inch comb). Bellies are usually about 13-inches wide but are oftenas much as 17-inches wide, which is wider than even the widest comb 50.When the pork belly is wider than the hanger 50, either a fat side foldover 54, as seen in FIG. 2B or a lean side fold over 56, as seen in FIG.2C.

Belly foldovers 54 and 56 are less likely to occur when the comb isinserted within 1/2 inch to 1 inch from the end of the pork belly 52, asseen in FIG. 2A. Since most meat processing companies expect employeesto insert the hanger/combs at a very fast rate, the combs 50 are ofteninserted farther away from the end of the pork belly 52, which can causefoldovers 54 (FIG. 2B) and 56 (FIG. 2C.) Further, during the time frominjection to the end of the smokehouse processing, the weight of thepork belly 52 on the comb 50 causes the pork belly to stretch andnarrow, as seen in the stretched portion 58 in FIG. 1. However, thetop/flank end or “upper portion” 62 of the pork belly 52 will notstretch/narrow because the tines/hooks of the comb keep that upperportion 62 dimensionally stable. Immediately after hanging, gravitybegins stretching and narrowing the belly 52. This continues during theheating/smoking process. Eventually with higher temperatures, the finaldimensions, by partially denaturing the protein, are fixed. Subsequentchilling brings the slab to a nearly frozen and nearly inelasticsemi-solid state.

Using wider combs 50 can limit foldovers 54 and 56, but maydetrimentally result in wedge-shaped pork bellies 60, as seen in FIG. 3.The combination of using wide combs 50 and less than optimal placementof the comb tines 51 into the pork belly 52 aggravates issues inherentwith bacon pressing because pork bellies 52 smoked/heated and chilledwith combs 50 placed as seen in the examples in FIGS. 2B and 2C, andFIG. 3 will become mostly inelastic during these processes. Due to thehigh forces compressing the belly in the press, these slabs may bedamaged and may produce damaged slices. Removing damaged slices thatfail to make the grade reduces slicing yields. Also, many slices thatare not acceptable for packaging may be unintentionally packaged asfirst quality product because unacceptable slices in a draft may becovered by good slices, resulting in consumer dissatisfaction. In short,damaged slices reduce yield, quality, or both.

The present invention produces a higher percentage of first qualityslices per slab after smoking/heating, chilling, and slicing. Thisinvention includes a system for better controlling the key dimensions ofthe pork belly 52, throughout the processing steps from injectionthrough chilling and to the point of slicing, so that slabs will requireminimal dimensional changes in the bacon slab pressing device.

FIG. 4 depicts a basic embodiment of the present invention of a meatprocessing device 70 having a frame 72, a number of frame tines 74, afirst shoulder 76, a second shoulder 78, and a hanging hook 80. Theframe 72 includes a first end portion 82 to which the first shoulder 76is joined, a second end portion 84 to which the second shoulder 78 isjoined, and a central portion 86 between the first end portion 82 andthe second end portion 84. In the illustrated embodiments, the meatprocessing devices are used to secure pork bellies 52 duringsmoking/heating and/or chilling processes.

The frame 72 and other components can be made of any suitable materialsuch as stainless steel, and be shaped in any suitable manner such asbent and welded wire, formed or laser-cut plate material, or machinedplate, or any combination of these, as examples. The basic embodimentdepicted in FIG. 4 is made from welded wire, but machined and formedplate versions are described below. The welded wire embodiment depictedin FIG. 4 has the frame 72, the frame tines 74, the first shoulder 76,and the second shoulder 78 all joined together and formed by bendingsome of the welded wires to the desired shapes.

In the illustrated embodiments, the first shoulder 76 is joined to themost distal end of the first end portion 82, but the first shoulder 76could be joined inwardly from the distal end of the frame 72 or evenhave another component disposed between the first end portion 82 of theframe 72 and the first shoulder 76 depending upon the desireddimensions. Similarly, the second shoulder 78 and the second end portion84 could be joined together in these various ways.

The meat processing device 70 is shaped so the pork belly 52 ispositioned at the center portion 86 where there are preferably a numberof frame tines 74 to impale or partially impale the cutaneous trunciimuscle, which is preferably positioned directly above the frame tines74. In this embodiment of a meat processing device 70, the firstshoulder 76 and the second shoulder 78 are arranged at right angles tothe frame 72. Each side of the pork belly 52 that would otherwise extendbeyond the first portion 82 and the second portion 84 of the frame 72 isinstead compressed by the respective shoulder 76/78, so the pork belly52 fits in the confinement space 90 between the first shoulder 76 andthe second shoulder 78 of the meat processing device 70.

The frame tines 74 are also depicted as being wires bent to a desiredshape and a slightly upward orientation with sharpened end portions 88.Any desired number of frame tines 74 can be used, so long as the porkbelly 52 is secured in the device 70. Also, the frame tines 74 can anyshape, width, material, or have any feature that secures a pork belly 52to the meat processing devices within the scope of the presentinvention. The frame tines 74 need not pierce the pork belly 52, butpiercing is preferred, especially when the pork belly 52 is hanging fromthe meat processing device. In the embodiments where the meat processingdevice is at the bottom and hanging from the pork belly 52, piercing maynot be necessary. Further, it is possible with the present invention touse only one frame tine 74, especially one that extends laterally toengage the meat in a uniform position.

The frame 72 and at least one of the first shoulder 76 or the secondshoulder 78, or both, cooperate to define a confinement space 90 inwhich an end portion of a pork belly 52 is secured to the frame tines74, but limited by the shoulder 76/78 from extending outwardly from theconfinement space 90 during heating, smoking, and chilling processes.Preferably, both the first shoulder 76 and the second shoulder 78 areused to define the confinement space 90, but only one or the other maybe used in some embodiments.

Maintaining an end of the pork belly 52 in the confinement space 90 andsecured to the frame 72 reduces the amount of foldover 54/56 (see FIGS.2B and 2C), stretched portions 58 (FIG. 1), and wedge-shaped bellies 60(FIG. 3) by maintaining the dimensions of the pork belly 52 duringprocessing when the pork belly 52 loses its elasticity in thesmokehouse. Further, controlling the width of the pork belly 52 while itis still pliant using the frame 72 and shoulder 76 combination, enablesworkers to secure the pork bellies 52 to the meat processing device 70quickly in a uniform and predetermined position, which enables racks ofpork bellies 52 to be uniformly hung and treated, as described in moredetail below.

Another embodiment of meat processing device 170 to control the shape ofthe top end of the pork belly 52 is illustrated in FIG. 5. This meatprocessing device 170 is used to control the top end of the pork belly52, and to be hung from a rack or trolley (see: FIG. 39, for example.)

The meat processing device 170 of FIG. 5 (as compared to the meatprocessing device 70 of FIG. 4) preferably further includes a cover 100hinged to the frame 70 at a hinge 102 or in any suitable manner, so thatthe cover 100 can move between an open position (FIG. 5) and a closedposition to further define at least a portion of the confinement space90. The cover 100 is joined to the frame 72 at a hinge 102, and thecover 100 includes a first portion 104 and a second portion 106. Thecover 100 can be any suitable shape, but is preferably bent into twoplanes so that it creates a three-dimensional confinement space 90 withthe frame 72 and one or both shoulders 76 and 78. Further, a hanginghook 80 can be used, and joined to the cover 100.

With the cover 100 in the open position (FIG. 5), the CT muscle of thepork belly 52 is pushed onto the frame tines 74, which are illustratedas straight, but could be angled relative to the frame 72, curved, orany other shape. Each side of the upper flank end of the pork belly 52is compressed to fit into the confined space 90 between the shoulders76/78 and onto the frame tines 74. The cover 100 is then pivoted to theclosed position to further secure the pork belly 52 in the confinementspace 90. The cover 100 preferably includes cover tines 108. The covertines 108 prevent surface muscles from folding forward or sliding downduring smoking/heating. The cover tines 108 can be in the form of any ofthe options described herein related to the frame tines 74.

The cover 100 is pushed closed to bring cover tines 108 to furtherimpale or otherwise entrap the pork belly 52 with the frame tines 74.This opposing tine arrangement holds the pork belly 52 in place toeliminate the “foldovers” shown in FIGS. 2B and 2C. The opposing frametines 74 and cover tines 108 can be angled so that they are orientedslightly upwardly when the pork belly 52 is hung to reduce the chancethat the pork belly 52 can drop out of the meat processing device 170,and so that the muscles on the surface of the lean side can not slidedownward when hung and heated.

The cover 100 is illustrated as being joined to the frame 72 with ahinge 102, but the cover 100 could be a separate component that detachesfrom the frame 72 for convenience and hygiene purposes. Rather thanpivoting into a closed position, a separate cover 100 could simply snapinto place or be attached using a connector to define the confinementspace 90. Other cover 100-to-frame 72 attachment mechanisms are alsopossible, including a hinge on the side of the frame 72 or one of theshoulders 76 and 78. The cover 100 could also slide into engagement withthe frame 72 using slots or recesses with mating tabs or flanges.Various types of tools and fixtures can also be used to position thevarious components and/or the meat to enable easier and quickerattachment of the meat to the meat processing devices 170 and/or 270.

The finished width of the pork belly 52 is recommended to be in therange of nine to ten inches because package sizes for sliced bacon arenormally in that range. Some bacon is made from smaller bellies thatresult in slices as short as six inches and packaged as center cutbacon. The meat processing device 170 and others within the scope ofthis invention could be dimensioned to correspond to any desired size ofpork bellies 52 or bacon size.

The meat processing device 270 of FIG. 6 does not include a hook and isused at the bottom of the pork belly 52, but is otherwise similar to themeat processing device 170 of FIG. 5. Not as many tines are necessary inthis embodiment because the meat processing device 270 does not supportthe weight of the pork belly 52.

The meat processing device of FIG. 7 is essentially the same as theembodiment of FIG. 5, except that the first shoulder 76 and the secondshoulder 78 are tapered. With this shape of shoulders 76/78, theresulting confinement space 90 will be tapered, as well, when the cover100 is closed.

Typically, about the last one inch of a pork belly 52 slab cannot besliced into acceptable slices because the slicing machine mechanismusually loses control of the pork belly 52 slab when slicing reachesthis point. Also, there are usually comb tine holes in this area of thepork belly 52 slab, which are very undesirable to the consumer. Theembodiment illustrated in FIG. 7 reduces the amount of the lossencountered at the trailing end of the bacon slab during slicing byreducing the thickness of the slab during the last two inches of thetrailing or flank end of the bacon slab. This is accomplished by anglingone or both shoulders 76/78 relative to the frame 72 to change or taperthe shape of the resulting confinement space 90. Preferably, a taper ofabout 1⅝ inches at the bottom to about 1 inch at the top end of thedevice is suitable, but other taper angles can be used.

Another embodiment of a top meat processing device 170 is illustrated inFIG. 8 to progressively narrow the width of the pork belly 52 slab forabout the last two inches of the trailing end which is the flank end 24of the pork belly 52 slab. This is accomplished by angling the shoulders76/78 relative to the frame 72 so the meat processing device 170 tapersfrom approximately 91/2 inches wide to approximately six inches wide.This tapered confinement space 90 reduces the volume of the end of slablost and thereby increases the percentage of the total useable weight ofthe pork belly 52 slab.

FIG. 9 is directed to a meat processing device 170 having a frame 72,frame tines 74, a first shoulder 76, a second shoulder 78, and a hook80. In addition, the embodiment of FIG. 9 includes a fixed cover 100that defines a top to the confinement space 90. This arrangement limitsthe position of the top of the pork belly 52 to the cover 100 position.This arrangement reduces the amount of waste by maintaining the frametine 74 engagement of the pork belly 52 to any desired dimension, butpreferably to less than one inch.

The brisket end 64 of the pork belly 52 is preferably enclosed in device270 of FIGS. 6, 10 and 11, and 28 to 38 if desired, so the pork bellylower end 55 is shaped flat during the smokehouse processing procedure.One embodiment of such a meat processing device 270 in accordance withthe present invention is illustrated in FIG. 10 and is attached to thelower portion 64 (usually the brisket end) of the pork belly 52 to putpressure against the muscles in this location so that they remain flatagainst the bottom 106 of the meat processing device 270. Normally, thecut muscles at the bottom/brisket portion 64 stretch to differentlengths resulting in a very uneven end of the pork belly 52. Thepressing machine (not illustrated) procedure attempts to eliminate thisend loss, but is only partially successful. The meat processing device270 of FIG. 10 includes a frame 72, optional shoulders 76 and 78, abottom portion 106 hinged to the frame 72, and a cover 104 hinged to thebottom portion 106. In this embodiment, the frame tines 74 are attachedto straps 75, which are joined to the frame 72. Another set of straps 77with tines 108 can be used as well.

FIG. 11 illustrates another meat processing device 270 embodiment thatis held tight against the bottom of the pork belly 52 during hanging, byspring-loaded hooks 110 attached to an upper meat processing device 170.The hooks 110 need not be spring-loaded, but springs 111 aid in applyingtension to the device 270 for improved support. The hooks 110 can be anylength and they may attach to the meat, but preferably attach to a meatprocessing device 170 joined to the top of the meat, as taught herein.

Hanging of the pork belly 52 slabs allows the rest of the pork belly 52slab to conform to the width dimension of the flank end device 170.These devices and embodiments increase the slicing yields of the baconslab.

FIGS. 12 to 19 illustrate a meat processing system in accordance withthe present invention, and the system includes both meat processingdevices 170 and 270 attached to a pork belly 52. The meat processingdevice 170 is joined to a top or flank end portion 62 of the pork belly52, and the meat processing device 270 is joined to the bottom orbrisket end portion 64 of the pork belly 52. Both of the meat processingdevices 170 and 270 define confinement spaces 90 in which the respectiveend portion 62 and 64 is confined for processing in a smokehouse. Also,both of the meat processing devices 170 and 270 have the same generalcomponents as those described above for the embodiments of FIGS. 4through 11, except for the modifications described below.

As seen in FIGS. 20 through 27, the meat processing device 170 on topincludes a frame 72, frame tines 74, a first shoulder 76, a secondshoulder 78, a hanging hook 80, and a confinement space 90. Thisembodiment of the top meat processing device 170 is made of bent andmachined stainless steel plate for rigidity and durability, but othermaterials and manufacturing methods can be used.

The frame 72 has a plate structure and the first shoulder 76, the secondshoulder 78, the tines 74, and the handle 80 are all preferably formedfrom the same plate and bent to the illustrated shape. In addition, theembodiment illustrated in FIGS. 20 through 27 includes a handle 110 tomake it easier to lift and hang the meat processing device 170 with apork belly 52 onto a rack, as illustrated below in relation to FIG. 39.The handle 110 can include a comfort feature 114 of a rounded edge, sothat the edge of the plate forming the handle 110 is not uncomfortableto hold.

Further, the first shoulder 76 and the second shoulder 75 each includeextensions 116 that extend inwardly, and above the confinement space 90.Each extension 116 includes a hinge tab 118 extending upwardly, and eachhinge tab 118 defines a hinge hole 122, as part of the hinge 102. Thecover 100 includes a pair of outwardly extending hinge projections 124,and each hinge projection 124 extends through a mating hinge hole 122 toform a hinge 102. Other hinge designs can be used in the presentinvention.

The cover 100 includes cover tines 108, and preferably a pair of pushtabs 132 to assist in piercing the pork belly 52 with the cover tines108. Preferably, a stop 109 is used to prevent over travel by the cover100, as seen engaging the push tabs 132 in FIGS. 20 to 22, for example.

These meat processing devices control the shape of the ends of the porkbelly 52 slab, so they are quite uniform after being processed in thesmoker. Additionally, the pork belly 52 becomes longer and narrowerwhile hanging on a rack during holding after injection and during thesmokehouse process. The meat treatment devices constrain the end of araw pork belly 52 that is up to seventeen inches or more wide at theflank end to a width of nine or ten inches wide after heating andchilling. The pork belly 52 slab will have substantially improveddimensional uniformity and stability.

The meat processing device in FIGS. 28 to 36 is able to form the brisketor lower end of the bacon slab so that it is flat and squared. Manyslabs will only lose one slice before slices will be acceptable to bepackaged as first quality product using this device 270.

In FIGS. 28 through 38, the meat processing device 270 is used at thebottom 64 of the pork bellies 52 (See FIGS. 13 through 19.) This meatprocessing device 270 does not require a hanging hook because it simplyattaches to the bottom 64 of the pork belly 52 to confine the shape ofthe bottom portion 64. This meat processing device 270 is optional whenthe top meat processing device 170 is used, but it is used to provide auniform shape to the pork belly 52. Further, this bottom meat processingdevice 270 can be used alone, without the top meat processing device170.

The bottom meat processing device 270 is similar in function to thebottom meat processing device of FIG. 10, and includes a frame 72, frametines 74, a first shoulder 76, a second shoulder 78, a cover 100 joinedto the frame 72 at a hinge 102, cover tines 108, and a confinement space90. This embodiment of the meat processing device 270 is formed ofstainless steel plate, and is cut, milled, and bent into the variousshapes illustrated. Nonetheless, other materials, shapes, andmanufacturing methods are possible.

The frame 72 includes a first end portion and a second end portion withholes to reduce weight and allow the smoking process to act on the lowerportion 64 of the pork belly 52. Frame tines 74 are preferably providedin a double row (FIG. 35), and are machined out of, or are otherwisejoined to, the frame 72 and bent or otherwise oriented downwardly whenattached to the pork belly 52. The illustrated frame 72 also includesframe flanges 272 that add rigidity to the meat processing device 270,as well as provide a convenient stand (see FIGS. 31 through 38) whilethe pork belly 52 is being inserted into the confinement space 90.

The cover 100 in this embodiment is formed by two halves, a first halfcover 280 and a second cover half 282 to make it easier to close thecover 100. Each cover half 280/282 includes cover tines 108 and isjoined to the frame 72 at a hinge 102.

The hinge 102 includes hinge tabs formed with or joined to the frame 72.The hinge tabs 118 define hinge holes 122 into which hinge projections124 on the cover halves 280 and 282 extend. To accommodate the hingeprojections 124 on the interior portions of the cover halves 280/282, apair of central hinge plates 288 are either formed from or joined to theframe 72. The hinge 102 can be formed in other ways and even be aseparate component used to join the cover 100 for pivoting movement tothe frame 72.

The frame tines 74 and the cover tines 108 are intended to pierce thepork belly 52 to grip the meat and entrap the lower end 64 of the porkbelly 52 in the confinement space 90. Nonetheless, only the weight ofthe meat processing device 270 needs to be supported, so the tines 74and 108 need not necessarily pierce the pork belly 52, and may be usedto simply engage or grip the pork belly 52 during use.

To further improve engagement of the meat processing device 270 to thepork belly 52, the cover 100 can be locked into a closed position (FIGS.28 to 38) using a releasable locking mechanism 290 to clamp down on themeat, for example. The releasable locking mechanism 290 preferablyincludes a shoulder lock component, such as recesses or holes 292arranged in an arc-shaped pattern in one or both of the first shoulder76 or the second shoulder 78. A mating cover lock component, such as atab 294 is attached to or part of the cover 100, so that pivoting thecover 100 (or cover halves 280 and 282) about the hinge 102 brings themating tab 294 into engagement with at least one of the holes 292.

Resiliency in either the frame 72, shoulders 76/78, or the mating tab294 provides releasable engagement between the two. Resiliency furtherenables the mating tab 294 to engage successive holes 292 so that thecover 100 can be releasably locked into a variety of positions (seeFIGS. 31 to 34) to close down the confinement space 90 and accommodatepork belly 52 lower ends 64 of varying thicknesses, especially when usedwith a pair of cover halves 280/282. Flexing the shoulders 76/78outwardly using flanges 298 releases the mating tab 294 from a hole 292so the cover 100 can be opened. (See FIGS. 35 and 36 for the openposition.) Other locking mechanisms 290 can be used, including thosehaving other shoulder lock components or other cover lock components,but the illustrated embodiment is simple to manufacture, use, and clean.Further, a locking mechanism could be used on the top meat processingdevice 170, if desired.

FIGS. 36 and 37 illustrate slightly different versions of the bottommeat processing device 270 of FIGS. 34 and 35, but the differences areprimarily in the shapes of the components and not in function.

Once the top and bottom meat processing devices 170 and 270 are attachedto pork bellies 52, they are transferred to racks or trolley 300, asseen in FIG. 39. The present invention results in an efficientspace-saving arrangement of pork bellies 52 on the trolleys 300, so theycan be rolled into a smoker and processed efficiently and uniformly withoptimum yields.

In addition to the yield increases and quality improvement with thisinvention there are significant capacity benefits. For baconmanufacturers, a common 3×2 hanging pattern with the two lower levellayers nested between the three upper layers. The preferred upper hangerFIG. 39 is 2 to 3 inches shorter in height when hanging than bacon combscurrently in routine use in the bacon industry. Because of this andbeing able to modify existing trolleys/racks as currently used in moststationary smokehouses by raising the upper level hanging bars 2 to 3inches and lowering the lower level hanging bars by 2 to 3 inches twolayers of bellies are able to be hung on a trolley/rack, withoutnesting, as depicted in FIG. 39. Also, because of the much narrowerhanging procedure/devices, four rows of bellies are able to be hung oneach layer without nesting instead of the current 3×2 hanging pattern.This is a 60% capacity increase on each trolley. This translates into a60% increase in pounds processed during each smokehouse and chillingcell cycle. Significant reductions in heating and chilling costs, smokeemissions, and smokehouse and chill cell cleaning chemicals used perpound of product produced are additional benefits. Significantly morebacon can be produced with the current equipment, thereby not needing torequire a facility expansion for these two areas until bacon demandexceeds the new increased capacity.

FIGS. 40 through 44 illustrate another embodiment of a top meatprocessing device 370 in accordance with the present invention,including: a frame 372; frame tines 374; a first shoulder 376; a secondshoulder 378; a first top flange 379; and a second top flange 381. Thisembodiment of the top meat processing device 370 can be constructed ofthe same materials and in essentially the same manner as described inthe above embodiments, except as described below.

The top meat processing device 370 also includes a hanging hook 380, afirst end portion 382, and a second end portion 384. A confinement space390 for an upper portion of a pork belly 52 is defined by the frame 372,the first shoulder 376, the second shoulder 378, the first top flange379, and the second top flange 381.

In this embodiment, the first shoulder 376 and the second shoulder 378are flared outwardly from the frame 372 at their respective distalportions to make inserting a pork belly 52 into the confinement space390 somewhat easier and provide a guide for aligning the pork belly 52as the pork belly 52 is pressed onto the tines 374, as best seen inFIGS. 42 and 44.

Further, like the extensions 116 and flanges 272 in the above-describedembodiments (see FIGS. 19 through 25, for example), the first top flange379 and the second top flange 381 define an upper boundary to preventthe pork belly 52 from being attached to the top meat processing device370 above the cutaneous trunci muscle. Thus, the pork belly 52 iscompressed into the confinement space 390 at the proper position toconnect the tines 374 to or close to the cutaneous trunci muscle withoutexcessive waste of pork belly 52. This is especially useful in a typicalmeat processing plant having a quality standard that rejects pork bellyportions with tine holes or even the area between the tine holes and theend of the pork belly 52. In such a plant, any part of the pork bellypositioned between the tines 374 and the end of the pork belly 52 willbe considered a “slicing loss.” Two top flanges 379 and 381 areillustrated, but a different number of top flanges could be used andthey can be joined to one or both of the shoulders 376, 378, if desired.The pork belly 52 abuts the shoulders 376, 378, as well as the topflanges 379 and 381 to substantially fill the confinement space 390 whensecured as described below.

Further, as illustrated in this and other embodiments, the tines 374preferably extend only part way across the confinement space 390, sothat the pork belly 52 is secure, but the tines 374 do not pierce thepork belly 52 completely and risk injuring a worker.

The first shoulder 376 and the second shoulder 378 each define at leastone notch 386 for receiving a retaining member 392 to secure the porkbelly 52 in the confinement space 390. The retaining member 392 can be apin, as illustrated herein, or a bar, a rod, or any other elongatedmember that retains the pork belly in place without covering the porkbelly 52 excessively, in a way that interferes with the smoking process.Preferably, a notched slot 398 is defined by the first shoulder 376, andmore than one notch 386 is defined in each notched slot 398 to permit anappropriate pair of notches 386 to be used depending on the pork belly52 thickness and shape.

As seen in FIG. 41, the retaining member 392 is used to maintain thepork belly 52 on the tines 374 and in the confinement space 390. Theretaining member 392 preferably bears on the side of the pork belly 52,and does not pierce the pork belly under typical usage. The retainingmember 392 extends between the first shoulder 376 and the secondshoulder 378. The retaining member 392 engages at least one notch 386 oneach of the first and second shoulders 376 and 378. As illustrated inFIG. 41, the notches 386 engaged by the retaining member 392 need not bedirectly opposite one another so that the retaining member 392 can bedisposed at any angle to accommodate a pork belly 52.

As seen in the embodiment illustrated in FIGS. 40 to 44, the notchedslot 398 is preferably oriented to extend from an upper rear portion toa lower front portion of each shoulder 376 and 378. With the notches 386formed in an upper edge of the notched slot 398, the retaining member392 can be used to compress the pork belly 52, and the pork belly 52opposes the retaining member 392 and biases the retaining member 392outwardly and into the contact with a notch 386.

The retaining member 392 is typically inserted into a notch 386 in oneshoulder to provide a pivot point and then leveraged into a notch 386 inthe opposite shoulder. Further, the illustrated arrangement allows anoperator to “ratchet” the retaining member 392 from one notch 386 toanother in the same shoulder to provide a secure connection that iseasily disassembled after the pork belly 52 has been removed from thesmoke house, simply by pulling one end of the retaining member 392laterally outwardly through the notches 386 in the first shoulder 376and the second shoulder 378. The retaining member 392 preferablyincludes a head 394 (FIG. 49) to provide a convenient handle.Preferably, the notches 386 are arranged relative to the tines 374, sothat the retaining member 392 is spaced away from the tips of the tines374 when releasably engaged in the notches 386 to ensure that the tines374 and the retaining member 392 are not too close to one another, andyet and provide secure engagement of the pork belly 52 on the tines 374.

As seen in FIG. 43, for example, the second shoulder notches 386 arejoined by a narrow slot. This narrow slot is not functional in relationto the present invention, and is only created for ease of manufacturing.Any suitable manner can be used to create the notches 386 and slots 398in the present invention.

FIGS. 45 through 48 illustrate a variation on the embodiment illustratedin FIGS. 40 through 44, in which the second shoulder 378 also defines anotched slot 398 with a plurality of notches 386 to substantially matchthe notches 386 in the first shoulder 376. The retaining member 392 canbe releasably engaged in notches 386 that are directly opposite oneanother or at other notches 386 so that the retaining member 392 can bedisposed at any desired angle to accommodate the shape of the porkbelly.

FIGS. 50 to 55 illustrate an alternate embodiment for a bottom meatprocessing device 470 having: a frame 472; one or more tines 474; afirst shoulder 476; a second shoulder 478; and a flange 479, which allcooperate to substantially define a confinement space 490 in which abottom portion of a pork belly 52 can be positioned and confined duringa smoking operation. The bottom meat processing device 470 alsopreferably includes a stand 495 for stability while a pork belly 52 isbeing secured.

Further, the tines 474 need not be very long to grip the pork belly 52enough to hold the bottom meat processing device 470 on the pork belly52. The tines 474 may penetrate the pork belly 52 only slightly or notat all and, therefore, not waste meat as would tines that mightpenetrate the meat more deeply.

FIG. 50 illustrates the device 470 resting on the stand 495 ready toreceive a pork belly 52, with the tines 474 extending upward in theconfinement space 490. The first shoulder 476 and the second shoulder478 are preferably each flared outwardly to define an outwardly flaredconfinement space 490, as described above in relation to the top meatprocessing device 370.

The first shoulder 476 and the second shoulder 478 each define a notchedslot 498, which has an upper edge that defines a number of pin notches486 that can be releasably engaged by a retaining member 392 (FIG. 51),as described above except that the pin notches 486 are not positionedbelow the tines 474. The notched slot 498 extends from an open front andouter end to a closed lower and rear end. One of the shoulders coulddefine just notches with no slot, if desired.

In addition to defining a portion of the confinement space 490, theflange 479 controls the shape of the pork belly 52 during smoking andchilling, so that the lower end of the pork belly is essentially evenand flat after processing, which helps create useable bacon slices atthe lower end of the pork belly 52.

FIG. 55 illustrates the device 470 attached to a lower end of a porkbelly 52, as it would appear hanging in a smoke house.

FIGS. 56 and 57 illustrate a nested storage arrangement of bottom meatprocessing devices 470, which is made possible by the outwardly flaredshoulders 476 and 478.

The foregoing detailed description of the invention is provided forclearness of understanding the drawings and the present invention, butno unnecessary limitations therefrom should be read into the followingclaims.

1. A meat processing device comprising: a frame having a first endportion and a second end portion; a shoulder joined to the first endportion of the frame to at least partially define a confinement spacewith the frame and the shoulder defines a notch; a frame tine joined toand extending outwardly from the frame and into the confinement space;and a retaining member removably disposed in the pin notch.
 2. The meatprocessing device of claim 1, and further comprising: a second shoulderjoined to the second end portion of the frame to at least partiallydefine the confinement space with the frame and the shoulder, and thesecond shoulder defines a notch in which the retaining pin is removablydisposed.
 3. The meat processing device of claim 1, and furthercomprising: a flange joined to the frame to at least partially definethe confinement space.
 4. The meat processing device of claim 1,wherein: the frame comprises a central portion between the first portionand the second portion; and at least a portion of the shoulder extendsaway from the central portion to define an outwardly tapered confinementspace.
 5. The meat processing device of claim 1, wherein the shoulderdefines a notched slot, and the notched slot defines the notch.
 6. Themeat processing device of claim 1, wherein the shoulder defines anotched slot, and the notched slot is open at a first end and closed ata second end.
 7. The meat processing device of claim 1, wherein theshoulder defines a notched slot, and the notched slot includes an upperedge that defines the notch.
 8. The meat processing device of claim 1,wherein the shoulder is disposed at an outward angle relative to theframe, and defines a notched slot, and the notched slot defines thenotch.
 9. The meat processing device of claim 1, wherein the shoulder isdisposed at an outward angle relative to the frame, and defines anotched slot extending from an upper rear portion to a lower frontportion of the shoulder, and the notched slot defines the notch.
 10. Themeat processing device of claim 1, wherein the shoulder defines anotched slot disposed at an angle and extending from an upper rearportion to a lower front portion of the shoulder and the notched slothas an upper edge that defines the notch.
 11. The meat processing deviceof claim 1, wherein the retaining member includes a pin.
 12. A meatprocessing device comprising: a frame having a first end portion, asecond end portion, and a central portion; a flange joined to the frame;a first shoulder joined to the first end portion of the frame, and thefirst shoulder defines a pin notch; a second shoulder joined to theframe, and the second shoulder defines a pin notch; at least a portionof each of the first shoulder and the second shoulder extends away fromthe central portion of the frame to at least partially define with theframe and the flange an outwardly tapered confinement space; a frametine joined to and extending outwardly from the frame and partiallyacross the outwardly tapered confinement space; and a retaining memberremovably extending between and disposed in the first shoulder pin notchand the second shoulder pin notch.